Abstract: A method of forming battery grids or plates that includes the step of mechanically reshaping or refinishing battery grid wires to improve adhesion between the battery paste and the grid wires. The method is particularly useful in improving the paste adhesion to battery grids formed by a continuous battery grid making process (such as strip expansion, strip stamping, continuous casting) that produces grid wires and nodes with smooth surfaces and a rectangular cross-section. In a preferred version of the method, the grid wires of battery grids produced by a stamping process are deformed such that the grid wires have a cross-section other than the rectangular cross-section produced by the stamping process. The method increases the cycle life of a battery.

Abstract: A stamped grid for a lead-acid battery having a grid pattern that is optimized for electrical performance. The stamped grid includes an electrically conductive grid body having opposed top and bottom frame elements, opposed first and second side frame elements and a plurality of interconnecting grid wire elements forming a grid pattern. The grid wire elements include a plurality of vertical wire elements connected to both top and bottom frame elements, a plurality of vertical wire elements connected to the top frame element and one of either the first or second side frame elements and a plurality of cross grid elements that interconnect the vertical wire elements. Each of the vertical grid elements that is connected to the top frame element and one of either the first or second side frame elements includes a plurality of the cross frame elements connected thereto at a substantially 90° angle.